Serving the Midlands, South West and Wales

Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

Company Directive

STANDARD TECHNIQUE: CA3V/4

Relating to Procedures for Making 33kV Cable

Terminations
Policy Summary

This Standard Technique document contains all the approved 33kV cold applied/cold pour
Terminations. It shall be implemented in conjunction with the appropriate General
Requirements in ST: CA3C/3.

This ST has not been written as a training document. It is not intended to be exhaustive in
content and you must refer to your supervisor if you require training or instruction.

You shall work safely and skilfully, utilising the training/instruction you have already
received, relating to the contents of this document and its cross-references.

You must make sure that you understand your job instructions and that you have the
necessary tools and equipment for the job.

All 185/300/400/630/800mm² OUTDOOR terminations shall be constructed in their final

erected position.

NOTE: The current version of this document is stored in the WPD Corporate Information Database. Any other
copy in electronic or printed format may be out of date. Copyright 2018 Western Power Distribution

ST:CA3V/4 October 2018 - 1 of 119 -

IMPLEMENTATION PLAN

Introduction

This updated Standard Technique defines all the standard 33kV terminations which are
available for use on the 33kV underground cable used within WPD.

Main Changes

 Ensto O/D Terminations - dimension change

Impact of Changes

No major impact.

Implementation Actions

Existing 33kV Jointers will need to be made aware of the new document.

Implementation Timetable

Immediate.

ST:CA3V/4 October 2018 - 2 of 119 -

REVISION HISTORY

Document Revision & Review Table

Date Comments Author
October 2018  Dimension for Ensto coldshrink terminations Richard Summers
changed to reflect manufacturers recommendations
August 2017  800mm2 terminations added Richard Summers
 Update and correction of minor dimensional errors
July 2017 Update and correction of minor dimensional errors. Richard Summers

March 2017 This is complete rewrite of the existing document. Peter White

ST:CA3V/4 October 2018 - 3 of 119 -

ST: CA3V/4 - PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

INTRODUCTION

This Standard Technique document contains all the approved 33kV Terminations, which
shall be implemented in conjunction with the appropriate General Requirements, contained
in ST: CA3C/3, including: -

1. General Cleanliness and Accident Prevention.

2. Joint Bay Preparation.

3. General Jointing Procedures – Dead Cables.

If the need arises to undertake a termination (i.e. non-standard) not covered within the
Standard Technique the Policy Manager, Avonbank, is to be consulted.

Where 240mm² cable is to be found, then for material selection and installation data use
300mm² cable; but for the electrical purposes i.e. loadings, ratings etc. then the 240mm²
cable shall be treated as 185mm².

Any reference to EPR equally applies to XLPE.

All crossing of cores will be undertaken outside of the cable box for Indoor Terminations
and below the cable cleat of the crucifix for Outdoor Terminations.

Earth Fault Indicators (E.F.I’s) are no longer fitted as standard, where there is a requirement
then the appropriate procedure/drawing shall be consulted.

Cable boxes that have single core glands on entries (as opposed to three core cable glands)
will require the base plate to be split and insulating material placed between the split
(prevention of circulating currents), alternatively the base plate is to be of a non-ferrous
metal i.e. in stainless steel, brass or aluminium.

NOTE:- All 185/300/400/630/800mm² OUTDOOR terminations shall be

constructed in their final erected position.

ST:CA3V/4 October 2018 - 4 of 119 -

CONTENTS

Description Page

7.401 185/300/400/630/800mm² CWS Single core – Indoor 6

(EFI optional)

7.402 185/300/400/630/800mm² CWS Single core – Outdoor 14

7.403 185/300mm² + 400/630mm2 CWS Single core – Compound 22

Filled

7.404 Not in use

7.405 185mm² CWS– (M)430 TB/G Separable. Connector 34

7.406 300/400/630/800mm² CWS – (M)440 TB/G Separable 49

Connector

7.407 630mm² CWS – (M)440TB/G (P2) Separable Connectors 64

(Back to back or piggy backed)

7.408 Installation of Euromold 400PB-10SA-36N outer cone 84

surge diverters.

7.409 185/300/400mm² CWS Single core Pfisterer Size 3 inner cone 90

connector termination.

7.410 630/800mm² CWS Single core Pfisterer Size 3XL inner cone 102
connector termination.

7.411 Installation of Pfisterer size 3 inner cone surge diverters. 115

ST:CA3V/4 October 2018 - 5 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.401

185/300/400/630/800mm² SINGLE CORE CABLE 33kV INDOOR

TERMINATION

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 6 of 119 -

 JOINTING PROCEDURE 7.401

TERMINATION KIT MATERIALS

CABLE SIZE: - 185/300/400/630/800mm² Cu. Single Core

Termination Kit Materials – Jointing Procedure 7.401

Termination Termination Termination
Taped
Cable Module Module Module Connector BET Insulated Earth Compression
Bushing Connector Tube Set
size CIT1.4204L CIT1.4205L CIT1.4206L 120-12 Stud gland zzzz
(set of 3)
(set of 3) (set of 3) (set of 3)
Copper
1 - 1 3 x VETB 21-12UTB 3 1 3 -
185mm²
Copper
1 - 1 3 x VETB 28-12UTB - 3 1 3 -
300mm²
Copper
- 1 1 3 x VETB 28-12UTB - 3 1 3 -
400mm²
Copper
- 1 1 3 x VETC 33-12UTB 3 1 3 3
630mm²
Copper 1
2 1 3 x VETC 44-120HUTB 3 1 3 3
800mm

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape
Scotch 70
Scotch 13 tape
Tinned copper wire 16 swg / 20swg
De-solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Cable ties
Sealing putty
Aluminium oxide cloth 320/400 grit
Copaslip

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV Jointing Manual.

ST:CA3V/4 October 2018 - 7 of 119 -

 JOINTING PROCEDURE 7.401

Actions General Requirements

(ST: CA3C/3)

Refer to drawings JP3D 7.401.1

1. Ensure cable box dimensions are suitable for terminations. 46

2. Identify and mark core phasing clear of termination position. --

3. Set and align cores into their termination positions, ensuring --

that any cross is undertaken well away from termination
position.

4. Clean each oversheath for a distance of 1.5m. --

5. Apply a temporary earth continuity bond clear of termination 11

position.

6. Park a mastic lined heat shrink tube next to temporary earth --

continuity bond of each core.

7. For Cu. conductors - park a compression gland over each cable 54

or park a heat shrink tube over each core.

8. Park gland plate and gland over cores. --

9. Set and mark cores into their required positions. 5/6

10. Cut each core 300mm above its connection point. --

11. Place a connector on each bushing, measure and mark --

internal depth of barrel onto outside of connector.

This mark becomes the reference point for the procedure.

12. Remove oversheaths and bedding tapes. 17

X
X = 380mm for 185-400mm2
X = 370mm for 630mm2/800mm2/1000mm2

ST:CA3V/4 October 2018 - 8 of 119 -

13. Abrade oversheaths. 18

14. Apply a turn of SMG 400 grey mastic tape around oversheaths. --

15. Straighten copper screen wires and bend back over

oversheath termination ensuring copper screen wires are
spaced evenly and bedded into mastic tape applied in 15. --

16. Apply three turns of 20 swg binder over copper screen wires --
at a point 480mm down from the reference point.

17. Apply a second layer of SMG 400 mastic tape over copper screen
wires and mastic tape applied in 15. --

18. Cover mastic tape and down the screen wires to the binding wire
applied in applied in 17 with two layers of PEE 225W tape and remove
binder --

19. Remove semi-conducting screens ensuring insulation

is free from all conductive material. 25

ST:CA3V/4 October 2018 - 9 of 119 -

20. Remove core insulation (depth of barrel +5mm). Fit lug to the
phase conductors; ensure connector palm is in correct position
to bushings before shearing bolts. 28/33

21. Thoroughly clean the insulation using wipes provided --

22. Apply SMG 400 mastic in the gap between the barrel of the
connector and the phase insulation ensure tape is level with
phase insulation. 50

23. Apply two layers of PEE 225W tape over the barrel of the connector
and SMG 400 tape applied in 24. Profile to reduce steps --

24. Apply silicon lubricant SSO 10 to PEE 225W cable insulation and
10mm on to the PEE 225W applied in 19. --

25. Apply termination body in line with the oversheath termination. 50

ST:CA3V/4 October 2018 - 10 of 119 -

26. Remove binder and flip over the skirt of the termination onto the mastic

27. Apply four turns minimum of Scotch 88 tape around copper --

screen wires 10mm below termination body. On top of the
Scotch 88 tape apply relevant phase colour PVC tape.

Do not apply PVC tape to the termination body.

28. Form copper screen wires into a bunch --

29. Apply build up tape to centralise cable within gland. 54

30. Fit gland plate to cable box. --

31. Connect phase connectors to bushings. --

32. Install BET lug onto each copper screen wire bunch
and connect to earth stud. 33

33. Position heat shrink breakout over gland and shrink into
position. 45

Note: - If an EFI is to be fitted move to action 36.

34. Connect switchgear/transformer earth to gland plate earth stud. --

35. Remove temporary earth continuity bond applied in 6 and reseal

oversheaths. 11/45

ST:CA3V/4 October 2018 - 11 of 119 -

36. Replace cable box cover ensuring all external bolt threads are treated
with “Copaslip” paste and security bolts are in place. --

ST:CA3V/4 October 2018 - 12 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.402

185/300/400/630/800mm² Cu SINGLE CORE CABLE 33kV OUTDOOR

TERMINATION

(This termination shall be constructed at its final erected position only.)

All overhead items for the crucifix etc. can be found in ST: OH4H/5 page 47
for the H pole and page 48 for the single pole arrangement.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 14 of 119 -

 JOINTING PROCEDURE 7.402
TERMINATION KIT MATERIALS

CABLE SIZE: - 185/300/400/630/800mm² Cu Single core.

Termination Kit Materials – Jointing Procedure 7.402

Termination
Surge Surge
Module Phase Connector Copper earth Cable cleat Cable cleat Cable cleat Cable cleat
Cable size Diverter Crucifix Arrester
COT14204 Connector BET 120-12 bar kit AR3-A35-TB AR3-A36-TB AR4-A37-TB AR4-A38-TB
(set of 3) Adaptor Plate
(set of 3)
185mm² 1 1 - -
3x
COT14204 1 1 1 3 1 -
VTPB 21-12 OHUTB
(set of 3)
300mm² 1 COT14204 3x - - -
1 1 1 3 1 1
(set of 3) VETC 28-12 OHUTB
400mm² 1 - 1 -
3x
COT1.4205L 1 1 1 3 1 -
VETC 28-12 OHUTB
(set of 3)
630mm² 1 - - 1
3x
COT1.4205L 1 1 1 3 1 -
VETC33-12 OHUTB
(set of 3)
2
800mm 1 1
3x
COT1.4206 1 1 3 1
VETC44-120HUTB
(set of 3)

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape / Scotch 70 / Scotch 13 tape

Tinned copper wire 16 / 20swg
De-solvit 1000 FD
De-solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Sealing putty
Aluminium oxide cloth 320 /400grit
Heavy-duty cable ties
Copaslip

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV Jointing Manual.

ST:CA3V/4 October 2018 - 15 of 119 -

 JOINTING PROCEDURE 7.402

Actions General Requirements

(ST: CA3C/3)

Refer to Drawing JP3D 7.402.6 whilst undertaking this Jointing Procedure.

1. Obtain required termination height and line phasing. --

2. Assemble crucifix and associated equipment and fit to pole

at the final position. 49

3. Run cables up the pole/H pole arrangement and cleat into

position. --

4. Set and cut cable to length. 5/6

5. Unravel and straighten individual cores. --

6. Identify and mark core phasing clear of termination position. --

7. Fit cable to crucifix, ensure any crossing is undertaken 22

below crucifix cable cleat.

8. Set and align cores into their termination positions. 22

9. Place a connector on each surge arrester adaptor plate, measure --

and mark internal depth of barrel onto outside of connector.

This mark becomes the reference point for the procedure.

10. Clean each oversheath for a distance of 1.5m. --

11. Remove oversheaths and bedding tapes. 17

12. Abrade oversheath for 50mm. 18

ST:CA3V/4 October 2018 - 16 of 119 -

13. Apply a turn of SMG 400 mastic tape around oversheath. --

14. Straighten copper screen wires and bend back over

oversheath termination ensuring copper screen wires are
spaced evenly and bedded into mastic tape. --

15. Apply three turns of 20 swg binder over copper screen wires
at a point 665mm down from the reference point.

16. Apply a second layer of SMG 400 mastic tape over copper screen
wires. --

17. Cover mastic tape seal with two layers of PEE225W tape
overlapping onto copper screen wires by 5mm. --

ST:CA3V/4 October 2018 - 17 of 119 -

18. Offer cores to reference point marked on connectors, mark
and cut cores. 27

19. Remove semi-conducting screens ensuring insulation is free from

all conductive material. 25

20. Remove core insulation (depth of barrel +5mm). Fit the lug and
connect to phase conductors; ensure connector palm is in correct
position to surge diverters adaptor plate before shearing bolts. 27/33

21. Thoroughly clean the insulation with DeSolvit 1000FD. 40

22. Apply SMG 400 mastic in the gap between the barrel of the
connector and the phase insulation ensure tape is level with
phase insulation. 50

23. Apply two layers of PEE 225W tape over the barrel of the connector
and SMG 400 tape applied in 21. --

ST:CA3V/4 October 2018 - 18 of 119 -

25. Apply silicon grease to the insulation for the length of the
first termination body and 10mm onto the PEE225W applied in 19. --

26. Apply first termination body CTSBGEL27-70L, remove the binder

and flip over the skirt. 50

27. At the end of the first termination body CTSBGEL27-70L

apply one layer of SMG 400 tape for a distance of 10mm. --

28. For a distance of 20mm and straddling the SMG 400 tape applied
in 27 apply two layers of 50% overlap PEE225W tape under
slight tension. --

ST:CA3V/4 October 2018 - 19 of 119 -

29. Apply silicon lubricant SSO 10 up to the first shed of the
first termination body over the insulation and the
PEE 225W tape applied to the cable lug. --

30. Apply second termination body CTSCGE27-70L leaving

a 30mm gap between the first shed and the end of the body. 50

31. Apply four turns minimum of Scotch 88 tape around copper

screen wires 10mm below termination body. On top of the
Scotch 88 tape apply relevant phase colour PVC tape. --

Do not apply PVC tape to the termination body.

32. Form copper screen wires into a bunch and remove 20 swg --
binder applied in 14.

33. Form copper screen wire bunches into one conductor 33

terminating into a earth connector, and connect to crucifix
earth stud.

ST:CA3V/4 October 2018 - 20 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.403

185/300mm² and 400/630mm2 SINGLE CORE CABLE 33kV COMPOUND

FILLED TERMINATION

(This Jointing Procedure also makes provision for Island Layer Assemblies)

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 22 of 119 -

 JOINTING PROCEDURE 7.403

TERMINATION KIT MATERIALS

CABLE SIZE: - 185/300mm² Single core

Item Quantity

185mm²

Connector VETB 21-12/16UTB 3

Connector BET-120 2
3M QT3 94-EP630-WPD (set of 3) 1
Sealing Sleeves WCSM 120/40 x 350 3
Resin Module RM-B 1
Silicon Compound 4.7 litres Quantity to suit Cable box
Earth Stud 1
Y Gland - non-ferrous 3

300mm²

Connector VETC28-12/16UTB 3
Connector BET-120 2
3M QT3 94-EP630-WPD (set of 3) 1
Sealing Sleeves WCSM 120/40 x 350 3
Resin Module RM-B 1
Silicon Compound 47 litres Quantity to suit Cable box
Earth Stud 1
Y gland – non-ferrous 3

CABLE SIZE: - 400/630mm² Single core

Item Quantity

400mm²

Connector VETC28-12/16UTB 3
Connector BET-120 2
Termination Module 3M QT3 94-EP640 (set of 3) 1
Sealing Sleeves WCSM 120/40 x 350 3
Resin Module RM-B 1
Silicon Compound 4.7 litres Quantity to suit Cable box
Earth Stud 1
Y Gland - non-ferrous 3

630mm²

Connector VETC33-12/16UTB 3
Connector BET-120 2
Termination Module 3M QT3 94-EP640 (set of 3) 1
Sealing Sleeves WCSM 120/40 x 350 3
Resin Module RM-B 1

ST:CA3V/4 October 2018 - 23 of 119 -

Silicon Compound 47 litres Quantity to suit Cable box
Earth Stud 1
Y gland – non-ferrous 3

Note: - Two part resin packs not used within Resin Module-B must be mixed before
disposal.

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape
Scotch 70
Scotch 13 tape
Tinned copper wire 16 swg
Tinned copper wire 20 swg
De-solvit 1000 FD
De-solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Cable ties
Sealing putty
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit
Copaslip
Siligasket

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual.

ST:CA3V/4 October 2018 - 24 of 119 -

 JOINTING PROCEDURE 7.403

CABLE BOX PREPARATION

Before commencing this jointing procedure the following points must be observed and
followed.

Where possible the existing cable box should be removed and replaced with new, a new
box to fit existing transformers/switchgear may be obtained from Webster Wilkinson Ltd,
the details are as follows: -

1. Establish the make and type of transformer/switchgear.

2. Contact Webster Wilkinson Ltd in Telford on 01952 585701 ask for Mr Kevin Allison
Sales Manager. Give details of the make and type of switchgear/transformer cable
box required. When ordering the new box ask for single cable entry and a stainless
steel gland plate, giving the diameter of hole size required to fit the appropriate
gland and insulated earth stud. The new cable box must come complete with
through bushings.

3. When installing the new gaskets siligasket is to be applied to both surfaces of the
new gasket prior to the gasket being fitted, this will provide a leak proof seal.

Where it is not possible to change the complete cable box, then the existing cable box must
be prepared as follows: -

1. Firstly the cable box needs to be ‘burnt out’ using infra-red lamps to heat up the G
38 and get it flowing, this needs to be captured to prevent an environmental issue,
the G 38 then needs to be disposed as hazardous waste. The cable box needs to be
cleared of the majority of the G38 looking for high 95-97% of G 38 removal, using
De-Solvit 1000FD will hasten the cleaning.

2. Ideally the plumbs should be removed from the Y glands so that they can be reused
for the cable this will mean they don’t have to find glands that fit, also the alignment
for the cables will be right for the connection points. The island layer of the
insulated gland can be removed so the gland becomes ‘solid’, unless frame leakage
protection is fitted to the switchgear.

3. The gland plate needs to be checked as being non-ferrous metal. If it is made from
ferrous metal it shall be replaced with a non-ferrous metal of similar configuration
and dimensions.

ST:CA3V/4 October 2018 - 25 of 119 -

4. Once the existing cables have been removed then the new flexible connections are
to be provided as the original flexibles are designed for two ½” BSF HTS fine screws
and nyloc nuts are fitted to each flexible. These shall be changed to one 12mm
stainless steel nut and bolt to marry up with the palm of the respective end
termination or lug.

5. With the new flexibles in place complete with the lug fitted in place the dimension
from the bottom of the lug’s barrel to the gland plate shall be checked there should
be 551mm. Place a connector on each flexible, measure and mark internal depth of
barrel onto outside of connector.

This mark becomes the reference point for the procedure.

6. If phase barriers are fitted which drop down to the gland plate then three insulated
brass studs shall be fitted to the gland plate E 5 No 41409.

7. All cork gaskets to be replaced with new cork gaskets when these gaskets are re-
applied then Sili-gasket E 5 No 42350 shall be applied on both surfaces of the cork
gasket to prevent the Lovisil from leaking out.

ST:CA3V/4 October 2018 - 26 of 119 -

 JOINTING PROCEDURE 7.403

Actions General Requirements

(ST: CA3C/3)

Refer to Drawing JP3D 7.403.1, 7.404.1, 7.403.2 and 7.403.3 whilst undertaking this
Jointing Procedure.

1. Ensure cable box dimensions are suitable for terminations. --

2. Remove existing and fit new cable box, alternatively prepare

existing cable box. --

3. Unravel and straighten individual cores. --

4. Identify and mark core phasing clear of termination position. --

5. Set and align cores into their termination positions, ensuring

that any cross is undertaken well away from termination
position. 5/6

6. Clean each oversheath for a distance of 1.5m. --

7. Apply a temporary earth continuity bond clear of termination

position. 11

8. Park a mastic lined heat shrink tube next to temporary earth

continuity bond of each core. --

9. Park a heat shrink sealing sleeve over cores. --

10. Park gland plate and gland over cores. --

11. Set and mark cores into their required positions. 5/6

12. Cut each core 300mm above its connection point. --

13. Place a connector on each bushing, measure and mark

internal depth of barrel onto outside of connector. --

Note: - This mark becomes the reference point for the procedure.

14. Remove oversheaths and bedding tapes. 17

15. Abrade oversheaths the full length of gland. 18

16. Apply a tum of mastic tape around oversheaths. --

ST:CA3V/4 October 2018 - 27 of 119 -

 JOINTING PROCEDURE 7.403 – Continued

Actions General Requirements

(ST: CA3C/3)

17. Straighten copper screen wires and bend back over oversheath
termination ensuring copper wire screens are spaced evenly
and bedded into mastic tape applied in 16. --

18. Apply three turns of 20 swg binder over copper screen wires
at a point 500mm down from the reference point. --

19. Apply a second layer of mastic tape over copper screen wires
and mastic tape applied in 16. --

20. Cover mastic tape seal with two layers of Scotch 88 tape
overlapping onto copper screen wires by 5mm. --

21. Offer cores to reference point marked on connectors,

mark and cut the cores. 27

22. Offer cores to reference point marked on connectors, mark

and cut cores. --

23. Remove semi-conducting screens ensuring insulation is free

from all conductive material. 25

24. Remove connectors from bushings or flexibles and connect to phase

conductors, ensure connector palm is in correct position
to the bushings or flexibles before shearing bolts. 33

25. Apply termination bodies. 50

26. Apply build up tape to centralise cable within gland. 56

27. Fit gland plate to cable box. --

28. Position heat shrink breakout over gland and shrink into 45
position.

29. Position cores into their final position maintaining a gap --

between each core and gland inner face.

30. Connect phase connectors to bushings or flexibles --

31. Fill gland with “Lovifit” glue and allow to harden. 39

32. Form copper screen wire bunches into one conductor terminating 36
into an earth connector, and connect to earth stud.

ST:CA3V/4 October 2018 - 28 of 119 -

 JOINTING PROCEDURE 7.403 – Continued

Actions General Requirements

(ST: CA3C/3)

33. Connect switchgear/transformer earth to gland plate earth stud. --

Note: - For Island layer assemblies the earth must be insulated

from the cable box steelwork.

34. Remove temporary earth continuity bond applied in 7 and reseal

oversheaths. 11/45

35. Replace cable box cover ensuring all external bolt threads are
treated with “Copaslip” paste. --

36. Fill cable box with Lovisil compound to required level and
replace filling cover; ensure external bolt threads are treated with
“Copaslip” paste. --

37. Mix and dispose correctly the un-used Pu resin. --

ST:CA3V/4 October 2018 - 29 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.405

185mm2 COPPER WIRE SCREEN 33kV EUROMOLD (M) 430 TB/G

INTERFACE C, 630A, SEPARABLE CONNECTOR TERMINATIONS.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 34 of 119 -

 JOINTING PROCEDURE 7.405

TERMINATION KIT MATERIALS LIST

CABLE SIZES —185mm2 Single core

Item Quantity

M 430 TB / G Series Separable Connector 630A (set of 3) 1

Connector BET 120-12 or BET 35-12 1
Atlas cable cleat AR2-A13-TB 3

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape
Scotch 70
Scotch 13 tape
Tinned copper wire 16 swg
Tinned copper wire 20 swg
De-solvit 1000 FD
De-solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Cable ties
Sealing putty
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit
Copaslip

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual.

ST:CA3V/4 October 2018 - 35 of 119 -

 JOINTING PROCEDURE 7.405

Actions General Requirement

(ST: CA3C/3)

Refer to Drawings JP3D 7.405.1, 7.405.2, 7.405.3, 7.405.4, 7.405.5, 7.405.6, 7.405.7,
7.405.8 and 7.405.9 whilst undertaking this Jointing Procedure.

1. Ensure cable box dimensions are suitable for termination. --

2. Identify and mark core phasing clear of termination position. --

3. Set and align cores into their termination positions. 5/6

4. Clean each oversheath for a distance of 2m. --

5. Apply a temporary earth continuity bond clear of termination

position. 11

6. Park a mastic lined heat shrink tube next to temporary earth.

continuity bond of each core. --

7. Park a compression gland and gland plate over each core. --

8. Set and mark cores into their required positions. 5/6

9. Cut each core 500mm above its connection point ensuring a

sufficient length of the copper screen wires for connection to
cable box earth stud. --

10. Place a connector onto each bushing, measure and mark

internal depth of barrel onto outside of connector. --

Note: - This mark becomes the reference point for the procedure.

11. Remove oversheaths and bedding tapes. 17

12. Abrade oversheaths. 18

13. Apply a turn of mastic tape around oversheath. --

14. Straighten copper screen wires and bend back over

oversheath termination ensure copper screen wires are
spaced evenly into mastic tape applied in 13. --

15. Apply three turns of 20swg binder over copper screen wires at a
point 275mm down from the reference point. --

16. Place a PVC tape marker 300mm from the reference point onto the
copper screen wires. --

ST:CA3V/4 October 2018 - 36 of 119 -

 JOINTING PROCEDURE 7.405 - Continued

Actions General Requirement

(ST: CA3C/3)

17. Offer cores to reference point marked on connectors, mark

and cut cores. --

18. Remove semi-conducting screens, ensuring insulation is free

from all conductive material. 25

19. Remove core insulation making a 3mm bevel to insulation end. 28

20. Apply a few turns of PVC tape to the conductor end as protection. --

21. Thoroughly clean core insulation. --

22. Apply field control mastic strip, type MFC, slightly stretch one end
applying with a 5mm overlap onto both semi-conducting screen and
core insulation, push the mastic in place while stretching it progressively
until both ends overlap and tear-off excess mastic. --

Note: - Ensure mastic does not break during application.

23. Apply the insulation coned rod to conductor end, thoroughly clean
coned rod and lubricate coned rod and core up to the MFC mastic tape. --

Note: - Alternatively the conductor can be coned using PVC tape

adhesive side up to start and tapered to insulation diameter, it is
important to apply a cover to the stranded conductor to prevent
internal damage to the bore of the reducer when applied.

24. Lubricate internal face (stepped end of the cable reducer, slide
reducer down the core without hesitation and in one smooth movement
until the end reaches the PVC tape marker applied in 16. --

25. Remove connectors from bushings and connect to phase conductors,

ensure connector palm is in correct position to bushings before
shearing bolts. 33

Note: - Check distance between top of connector and top of reducer is between 150 and
160mm. Adjust the reducer to suit.

26. Clean cable reducer, core insulation and connector. --

27. Lightly lubricate the inner surface of the tee connector housing
and cable reducer. --

ST:CA3V/4 October 2018 - 37 of 119 -

 JOINTING PROCEDURE 7.405 - Continued

Actions General Requirement

(ST: CA3C/3)

28. Check the angle of the tee connector housing is correct to connector
palm and longer interface is pointing towards the bushing.
Whilst supporting the cable reducer at its stepped end preventing
movement, gently slide the housing onto the cable until it cannot
advance any further.
Check correct installation by trying to pull back the connector, it is
correct when it stays in its locked position, also check to ensure cable
reducer has stayed in place during installation. --

29. Clean and lightly lubricate both inner face of connector housing
and bushing, push connector housing onto bushing. --

30. Insert clamping screw (longer thread) into threaded hole of bushing
and tighten. --

Note: - The screw must be tightened with a torque wrench exerting

50Nm of torque using a 22mm socket in order to achieve correct
torque, ensure there is to be no lubrication on the threaded parts.

31. Clean and lubricate plug and inner face of connector housing. --

32. Insert the plug into connector housing and tighten assembly. --

Note: - The plug must be tightened with a torque wrench exerting

30Nm of torque using a 22mm socket in order to achieve correct
torque, ensure there is to be no lubrication on the threaded parts.

33. Clean inside of protective cap and outer face of connector housing
and insulating plug. --

34. Push protective cap over connector housing onto the insulating
plug, slightly pull the edge of the protective cap to exhaust any air
whilst pressing cap centre onto its locking point until it snaps into
place. Position cap with the pulling tab facing downwards. --

35. Apply four turns of Scotch tape of the relevant phase colour
around the copper the screen wires 10mm below cable reducer end. --

Note: - Do not apply PVC tape to cable reducer or connector housing.

36. Form copper screen wires into a bunch, remove 20swg binder and
PVC tape binder applied in 15/16. --

ST:CA3V/4 October 2018 - 38 of 119 -

 JOINTING PROCEDURE 7.405 - Continued

Actions General Requirement

(ST: CA3C/3)

37. Fit gland plate to cable box. --

38. Fit compression gland to each core. 54

39. Form copper screen wires bunches into one conductor terminating into a
terminating into an earth connector, and connect to earth stud. --

40. Connect earth leads from connector housings to earth stud. --

41. Fit and secure cables into cable cleats. --

42. Connect switchgear/transformer earth to gland plate earth stud. --

43. Remove temporary earth continuity bond applied in 5 and reseal

oversheaths with heat shrink tubes applied in 6. 11/45

44. Replace cable box cover ensuring all external bolt threads are treated
with “Copaslip” paste and security bolts are in place. --

ST:CA3V/4 October 2018 - 39 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.406

300/400/630 and 800mm2 COPPER WIRE SCREEN CABLE 33kV EUROMOLD

(M) 440 TB/G INTERFACE C SEPARABLE CONNECTOR TERMINATIONS.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 49 of 119 -

 JOINTING PROCEDURE 7.406

TERMINATION KIT MATERIALS LIST

CABLE SIZES — 300mm2

Item Quantity

(M)440TB/G-32-120.300-14.5MWS Separable Connector 630A (each) 3

Connector BET 120-12 or BET 35-12 3
Cable cleat AR2-A13-TB 3

CABLE SIZES — 400mm2 CWS

Item Quantity

(M)440TB/G-37-TBMC-400.630-12.5MWS Separable Connector 630A (each) 3

Connector BET 120-12 or BET 35-12 3
Cable cleat AR2-A13-TB 3

CABLE SIZES — 630mm2 CWS

Item Quantity

(M)440TB/G-44-TBMC-400.630-12.5.MWS Separable Connector 630A (each) 3

Connector BET 120-12 or BET 35-12 3
Cable cleat AR2-A14-TB 3

CABLE SIZES — 800mm2 CWS

Item Quantity

(M)440TB/G-44-TBMC-400.800-12.5.MWS Separable Connector 630A (each) 3

Connector BET 120-12 or BET 35-12 3
Cable cleat AR2-A14-TB 3

Note: - The 800mm² (M) 440 TB/G uses a compression lug therefore ensure you have the
correct compression tool and dies sets before commencing work.

ST:CA3V/4 October 2018 - 50 of 119 -

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape
Scotch 70
Scotch 13 tape
Tinned copper wire 16 swg
Tinned copper wire 20 swg
De-solvit 1000 FD
De-solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Cable ties
Sealing putty
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit
Copaslip

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual.

ST:CA3V/4 October 2018 - 51 of 119 -

 JOINTING PROCEDURE 7.406

Actions General Requirement

(ST: CA3C/3)

Refer to Drawings JP3D 7.406.1, 7.406.2, 7.406.3 7.406.4, 7.406.5, 7.406.6, 7.406.7 and
7.406.8 whilst undertaking this Jointing Procedure.

1. Identify and mark core phasing clear of termination position. --

2. Set and align cables into their termination positions. --

3. Clean each oversheath for a distance of 1 .5m. --

4. Apply a temporary earth continuity bond clear of termination

position. 11

5. Park a mastic lined heat shrink tube next to temporary earth.

continuity bond of each core. --

6. Park a compression gland over each core. 54

7. Set and mark cables into their required positions. 5/6

8. Cut each cable 300mm above its connection point. --

9. Place a connector on each bushing, measure and mark internal --

depth of barrel onto outside of connector.

This mark becomes the reference point for the procedure.

10. Remove oversheaths and bedding tapes — Fig 1. --

11. Abrade oversheaths — Fig 1. --

12. Apply a turn of mastic around oversheath — Fig 1. --

13. Straighten copper screen wires and bend back over oversheath
termination ensure copper screen wires are spaced evenly and
bedded into mastic applied in 11. --

14. Apply three turns of 20swg binder over copper wires at a point
275mm down from the reference point. --

15. Place a PVC tape marker 245mm from the reference point onto the
copper screen wires — Fig 1. --

16. Offer cores to reference point marked on connectors,

mark and cut cores. --

ST:CA3V/4 October 2018 - 52 of 119 -

 JOINTING PROCEDURE 7.406 - Continued

Actions General Requirement

(ST: CA3C/3)

17. Remove semi-conducting screens, ensuring insulation is free

from all conductive material — Fig 1. 25

18. Remove core insulation making a 3mm bevel to insulation

end — Fig 1. 31

19. Apply a few turns of PVC tape to the conductor end as a protection. --

20. Thoroughly clean core insulation. --

21. Apply field control mastic strip, type MFC, slightly stretch one
end applying with a 5mm overlap onto both semi-conducting
screen and core insulation, push the mastic in place while
stretching it progressively until both ends overlap and tear-off
excess mastic — Fig 2 --

Note: - Ensure mastic does not break during application.

22. Apply the installation coned rod to conductor end, thoroughly

clean coned rod and lubricate coned rod and core up to the
MFC mastic tape — Fig 4. --

23. Lubricate internal face (stepped end) of the cable reducer, slide
cable reducer down the core without hesitation and in one smooth
movement until the end reaches the PVC tape marker
applied in 9—Fig 4. --

24. Remove connectors from bushings and connect to phase conductors,

ensure connector palm is in correct position to bushings before
shearing; before and after shearing check distance between top of
shearbolt connector and top of cable reducer is between 155 and
165mm see Fig 5. Adjust the reducer to suit 36

25. Clean cable reducer, core insulation and connector — Fig 6. --

26. Lightly lubricate the inner surface of the tee connector housing
and cable reducer — Fig 6. --

27. Check the angle of the tee connector housing is correct to

connector palm and longer interface is pointing towards the
bushing. Whilst supporting the cable reducer at its stepped end
preventing movement, gently slide the housing onto the cable
until it cannot advance no further — Fig 6. --

28. Check correct installation by trying to pull back the connector,

it is correct when it stays in its locked position, also check to
ensure cable reducer has stayed in place during
installation — Fig 7. --

ST:CA3V/4 October 2018 - 53 of 119 -

 JOINTING PROCEDURE 7.406 - Continued

Actions General Requirement

(ST: CA3C/3)

29. Clean and lightly lubricate both inner face of connector housing
and bushing, push connector housing onto bushing. --

30. Insert clamping screw (longer thread) into threaded hole of

bushing and tighten — Fig 8. --

Note: - The screw must be tighten with a torque wrench exerting a

50Nm of torque using a 22mm socket in order to achieve
correct torque, ensure there is to be no lubricate on the
threaded parts.

31. Clean and lubricate plug and inner face of connector

housing. Insert nylon venting rod into the connector interface. --

32. Insert the plug into connector housing, remove nylon venting rod
and tighten assembly - Fig 8. --

Note: - The plug must be tighten with a torque wrench exerting 50Nm
of torque using a 22mm socket in order to achieve correct torque,
ensure there is to be no lubricate on the threaded parts.

33. Clean inside of protective cap and outer face of the connector
housing and insulating plug. --

34. Push protective cap over connector housing onto the insulating
plug, slightly pull the edge of the protective cap to exhaust any
air whilst pressing cap centre onto its locking point until it snaps
into place. Position the cap with the pulling tab facing
downwards — Fig 8. --

35. Apply four turns of Scotch tape of the relevant phase colour
around copper screen wires 10mm below cable reducer end. --

Note: - Do not apply PVC tape to cable reducer or connector housing.

36. Form copper screen wires into a bunch and removing 20swg binder
and PVC tape binder applied in 13/14. --

37. Fit gland plate to cable box. --

38. Fit compression glands to gland plate and each cable. 60

39. Form copper screen wire bunches into one conductor terminating
into a earth connector, and connect to earth stud. 36

40. Remove temporary earth continuity bond applied in 4 and reseal

oversheaths. 51

ST:CA3V/4 October 2018 - 54 of 119 -

 JOINTING PROCEDURE 7.406 - Continued

Actions General Requirement

(ST: CA3C/3)

41. Replace cable box cover ensuring all external bolt threads are
treated with “Copaslip” paste and security bolts are in place. --

ST:CA3V/4 October 2018 - 55 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.407

300/400/630and 800mm2, COPPER WIRE SCREEN, 33kV EUROMOLD (M) 440

TB/G INTERFACE C, 1250A, in BACK to BACK CONFIGURATION SEPARABLE
CONNECTOR TERMINATIONS.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 64 of 119 -

 JOINTING PROCEDURE 7.407

TERMINATION KIT MATERIALS LIST

CABLE SIZES — 300mm2 CWS

Item Quantity

(M)440TB/G-32-120.300-14.5MWS Separable Connector 1250A (each) 6

(M)400CP-Connector Plug 3
Connector BET 120-12 or BET 35-12 6
Cable cleat AR2-A13-TB 6

CABLE SIZES — 400mm2 CWS

Item Quantity

(M)440TB/G-37-TBMC-400.630-12.5MWS Separable Connector 1250A (each) 6

(M)400CP-Connector Plug 3
Connector BET 120-12 or BET 35-12 6
Cable cleat AR2-A13-TB 6

CABLE SIZES — 630mm2 CWS

Item Quantity

(M)440TB/G-44-TBMC-400.630-12.5.MWS Separable Connector 1250A (each) 6

(M)400CP-Connector Plug 3
Connector BET 120-12 or BET 35-12 6
Cable cleat AR2-A14-TB 6

CABLE SIZES — 800mm2 CWS

Item Quantity

(M)440TB/G-44-TBMC-400.800-12.5.MWS Separable Connector 1250A (each) 6

(M)400CP-Connector Plug 3
Connector BET 120-12 or BET 35-12 6
Cable cleat AR2-A14-TB 6

Note: - The 800mm² (M) 440 TB/G uses a compression lug therefore ensure you have the correct compression
tool and dies sets before commencing work.

ST:CA3V/4 October 2018 - 65 of 119 -

ADDITIONAL ITEMS FOR EACH TERMINATION

PVC tape
Scotch 70
Scotch 13 tape
Tinned copper wire 16 swg
Tinned copper wire 20 swg
De-Solvit 1000 FD
De-Solvit 1000
Workhorse dry wipes
Emery cloth
5313 Water block tape
Cable ties
Sealing putty
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit
Copaslip

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual.

ST:CA3V/4 October 2018 - 66 of 119 -

 JOINTING PROCEDURE 7.407

Actions General Requirement

(ST: CA3C/3)

Refer to Drawings JP3D 7.407.1, 7.407.2, 7.407.3 7.407.4, 7.407.5, 7.407.6, 7.407.7,
7.407.8, 7.407.9, 7.407.10, 7.407.11, 7.407.12 and 7.407.13 whilst undertaking this Jointing
Procedure.

1. Identify and mark core phasing clear of termination position. --

2. Set and align cables into their termination positions. --

3. Clean each oversheath for a distance of 1 .5m. --

4. Apply a temporary earth continuity bond clear of termination 11

position.

5. Park a mastic lined heat shrink tube next to temporary earth.

continuity bond of each core. --

6. Park a compression gland over each core. 54

7. Set and mark cables into their required positions. 5/6

8. Cut each cable 300mm above its connection point. --

9. Place a connector on each bushing, measure and mark internal --

depth of barrel onto outside of connector.

This mark becomes the reference point for the procedure.

10. Remove oversheaths and bedding tapes — Fig 1. 17

11. Abrade oversheaths — Fig 1. 18

12. Apply a turn of mastic around oversheath — Fig 1. --

13. Straighten copper screen wires and bend back over oversheath --
termination ensure copper screen wires are spaced evenly and
bedded into mastic applied in 11.

14. Apply three turns of 20swg binder over copper wires at a point --
275mm down from the reference point.

15. Place a PVC tape marker 245mm from the reference point --
onto the copper screen wires — Fig 1.

16. Offer cores to reference point marked on connectors, --

mark and cut cores.

ST:CA3V/4 October 2018 - 67 of 119 -

 JOINTING PROCEDURE 7.407 - Continued

Actions General Requirement

(ST: CA3C/3)

17. Remove semi-conducting screens, ensuring insulation is free 25

from all conductive material — Fig 1.

18. Remove core insulation making a 3mm bevel to insulation

end — Fig 1. 27

19. Apply a few turns of PVC tape to the conductor end as a protection. --

20. Thoroughly clean core insulation. --

21. Apply field control mastic strip, type MFC, slightly stretch one
end applying with a 5mm overlap onto both semi-conducting
screen and core insulation, push the mastic in place while
stretching it progressively until both ends overlap and tear-off
excess mastic — Fig 2 --

Note: - Ensure mastic does not break during application.

22. Lubricate internal face (stepped end) of the cable reducer, slide
cable reducer down the core without hesitation and in one smooth
movement until the end reaches the PVC tape marker
applied in 9—Fig 4. --

23. Remove connectors from bushings and connect to phase conductors,

ensure connector palm is in correct position to bushings before
shearing- Fig 5. 33

24. Remove any burrs resulting from tightening. --

25. Clean cable reducer, core insulation and connector — Fig 6. --

26. Lightly lubricate the inner surface of the tee connector housing
and cable reducer — Fig 6. --

27. Check the angle of the tee connector housing is correct to

connector palm and longer interface is pointing towards the
bushing. Whilst supporting the cable reducer at its stepped end
preventing movement, gently slide the housing onto the cable
until it cannot advance no further — Fig 6. --

28. Check correct installation by trying to pull back the connector,

it is correct when it stays in its locked position, also check to
ensure cable reducer has stayed in place during
installation — Fig 7. --

29. Clean and lightly lubricate both inner face of connector housing
and bushing, push connector housing onto bushing.

30. Insert clamping screw (longer thread) into threaded hole of bushing
and tighten — Fig 8. --

ST:CA3V/4 October 2018 - 68 of 119 -

 JOINTING PROCEDURE 7.407 - Continued

Actions General Requirement

(ST: CA3C/3)

Note: - The screw must be tighten with a torque wrench exerting a

50Nm of torque using a 22mm socket in order to achieve
correct torque, ensure there is to be no lubricate on the
threaded parts.

31. Clean and lightly lubricate both, connector interface and

connecting plug interface. --

32. Push the connecting plug into the connector, engage the threads
and hand tighten - Fig 8. --

Note: - The plug must be tighten with a torque wrench exerting 50Nm
of torque using a 10mm hex key in order to achieve correct torque,
ensure there is to be no lubricate on the threaded parts.

33. Clean and lightly lubricate both, the second connector and the
connecting plug interface. Push the connector on to the
connecting plug. --

34. Insert the second 400TCS clamping screw (longer thread) into
threaded hole of the connecting plug and tighten. --

Note: - The screw must be tighten with a torque wrench exerting a

50Nm of torque using a 22mm socket in order to achieve
correct torque, ensure there is to be no lubricate on the
threaded parts.

35. Clean and lightly lubricate both, connector interface and

connecting plug interface. --

36. Push the connecting plug into the connector, engage the threads
and hand tighten. --

Note: - The plug must be tighten with a torque wrench exerting 50Nm
of torque using a 24mm socket in order to achieve correct torque,
ensure there is to be no lubricate on the threaded parts.

37. Clean inside of protective cap and outer face of the connector
housing and insulating plug. --

38. Push protective cap over connector housing onto the insulating
plug, slightly pull the edge of the protective cap to exhaust any
air whilst pressing cap centre onto its locking point until it snaps
into place. Position the cap with the pulling tab facing
downwards. --

ST:CA3V/4 October 2018 - 69 of 119 -

 JOINTING PROCEDURE 7.407 - Continued

Actions General Requirement

(ST: CA3C/3)

39. Apply four turns of Scotch tape of the relevant phase colour
around copper screen wires 10mm below cable reducer end. --

Do not apply PVC tape to the cable reducer or connector housing.

40. Form copper screen wires into a bunch and removing 20swg binder
and PVC tape binder applied in 13/14. --

41. Fit gland plate to cable box. --

42. Fit compression glands to gland plate and each cable.

43. Form copper screen wire bunches into one conductor terminating
into a earth connector, and connect to earth stud. --

44. Remove temporary earth continuity bond applied in 4 and reseal

oversheaths. --

45. Replace cable box cover ensuring all external bolt threads are
treated with “Copaslip” paste and security bolts are in place. --

46. Ensure all cables are adequately cleated and carry the weight
of the cables. --

ST:CA3V/4 October 2018 - 70 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.408

33kV EUROMOLD 400PB-10SA-36/45N INTERFACE C SURGE DIVERTER

SEPARABLE CONNECTOR.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 84 of 119 -

 JOINTING PROCEDURE 7.408

TERMINATION KIT MATERIALS LIST

SURGE DIVERTER — 400PB-10SA-36/45N

Item Quantity

400PB-10SA-35/45N Surge Diverter 3

These surge diverters are on C contract i.e. a call off purchase order
needs to be raised on Nexans to get these surge diverters.

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual.

ST:CA3V/4 October 2018 - 85 of 119 -

 JOINTING PROCEDURE 7.408

Actions General Requirement

(ST: CA3C/3)

1. If fitted remove the voltage cap, insulating plug. and clamping screw
(retain for later use) --

2. Remove the clamping screw and retain for later use --

ST:CA3V/4 October 2018 - 86 of 119 -

3. Clean and lubricate the inner interface of the tee connector using only
the supplied silicone lubricant. --

4. Insert the contact rod (first by hand to ensure the threads are correctly
engaged). Tighten the contact rod using a 10mm hex key and torque
wrench. Tighten to 50Nm. Do not contaminate the threaded parts with
lubricant. --

5. Lubricate the male cone of the surge diverter and plug into the back
Of the tee connector using only the supplied lubricant --

ST:CA3V/4 October 2018 - 87 of 119 -

6. Insert the clamping screw (first by hand to ensure the threads are
correctly engaged) before tightening to 30Nm with a torque wrench --

7. Clean and lubricate the inner cone of the diverter and the outer cone of
the insulating plug. Insert the nylon vent rod and then screw in the
insulating plug (by hand). Tighten the insulating plug to 30Nm before
removing the nylon vent rod. --

ST:CA3V/4 October 2018 - 88 of 119 -

8. Refit the voltage detection cap and connect the earth lead from the
surge diverter to earth. --

ST:CA3V/4 October 2018 - 89 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.409

185/300 and 400mm2 COPPER WIRE SCREEN CABLE 33kV PFISTERER SIZE 3
INNER CONE SEPARABLE CONNECTOR TERMINATIONS.

Note: - To complete this termination bespoke Pfisterer tooling is required.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 90 of 119 -

JOINTING PROCEDURE 7.409

MATERIALS LIST CABLE SIZE – 185, 300 and 400mm² CWS

Cable size 185mm² CWS

Item Quantity

Pfisterer inner cone size 3 base module (set of 3) 1

Pfisterer 185mm² cable size module 1
Connector BET120-12 or BET 35-12 1 or 3
Atlas two bolt cable cleat AR2-A12-TB 3

Cable size 300mm² CWS

Item Quantity

Pfisterer inner cone size 3 base module (set of 3) 1

Pfisterer 300mm² cable size module 1
Connector BET120-12 or BET 35-12 1 or 3
Atlas two bolt cable cleat AR2-A13-TB 3

Cable size 400mm² CWS

Item Quantity

Pfisterer inner cone size 3 base module (set of 3) 1

Pfisterer 400mm² cable size module 1
Connector BET120-12 or BET 35-12 1 or 3
Atlas two bolt cable cleat AR2-A13-TB 3

ADDITIONAL ITEMS FOR EACH JOINT

PVC Tape
De-solvit 1000 FD
Workhorse dry wipes
Emery cloth
Cable ties
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual

Note 2: - To complete this termination bespoke Pfisterer tooling is required e.g.

mechanical hydraulic compression tool, size 3 compression head, size 3 impact head and
SW6 Torx head screwdriver.

This jointing procedure is only to be used on cables with outside diameter > 58 mm
namely:-

Cable Size - CWS Outside Diameter of cable.

185mm² 42.5mm
300mm² 47.5mm
400mm² 50.8mm

ST:CA3V/4 October 2018 - 91 of 119 -

 JOINTING PROCEDURE 7.409

Actions General Requirements

(ST: CA3C/3)

1. Ensure cable box dimensions are suitable for termination. --

2. Identify and mark core phasing clear of termination position. --

3. Set and align cores into their termination positions. 6

4. Clean each oversheath for a distance of 2m. --

5. Heat and straighten cores 8

6. Apply a temporary earth continuity bond clear of termination 11

position.

7. Park a mastic lined heat shrink tube next to temporary earth

continuity bond of each core. --

8. Park heatshrink tube and pre-assembled bell assembly over cable. --

9. Set and mark cores into their required positions and mark position (1).
This position will be the datum mark for the whole termination 6

10. Cut each core to allow sufficient length of copper wire screen to
terminate to its earth connection point. --

ST:CA3V/4 October 2018 - 92 of 119 -

11. From the datum mark (1) previously applied in 9, place a
further mark 160mm towards the cable --

12. Remove oversheath and bedding tapes to datum (1). 17

13. From the oversheath termination mark 160mm --

14. From the datum line measure 270mm (160 +110mm)

and mark the position. Abrade between the two marks 16
.
15. Degrease the abraded area of 14. 39

16. Apply a tape control mark at 160mm (to outside edge as shown below)

17. Apply a turn of sealing tape 10mm behind the control mark --

18. At the datum line cut equalization tape from screen wires. --

ST:CA3V/4 October 2018 - 93 of 119 -

19. Straighten copper screen wires and bend back over oversheath
termination ensure copper screen wires are spaced evenly into
mastic tape applied in 17 --

NOTE: - Ensure screen wires DO NOT CROSS EACH OTHER.

20. Fix the copper screen wires in place on the oversheath

with the Scotch 88. Position this control mark 160mm back from the sheath
cut as shown above --

21. Remove the water swelling tape to the oversheath termination. --

EASI_STRIP Semi-Con Screen Only (for bonded screens see 29)

22. Place a mark 235mm from the oversheath termination

and cut the cable 24
235

NOTE: - The conductor shall be cut by hacksaw only.

23. Remove insulation screen 225mm from the core end and abrade
using Al. oxide (400 grit) 25

24. Chamfer the edge and degrease the insulation. 29

25. Apply adhesive tape (sticky side out) from the beginning of the insulation.
Ensure the edge is straight and clean.

ST:CA3V/4 October 2018 - 94 of 119 -

26. Wearing disposable gloves and using a new, clean workhorse wipe apply the dry
graphite (Pfisterer part number No. 003 010 011) to the roughened insulation.
Allow to dry before buffing off excess with a clean dry wipe

27. Remove protective Scotch 88 tape and proceed to XXXXX --

28. Stretch self-amalgamating semi-conductive over the screen termination ensuring

that 20mm is applied with a 50% overlap as shown below.

FULLY BONDED Semi-Con only

29. Place a mark 300mm from the oversheath termination and cut the cable 24

30. In the section between 250mm and 300mm in front of the sheath cut, strip off the
screen using the stripping tool. Determine the difference between the diameter of
the semi-con layer and the diameter if the insulation.

ST:CA3V/4 October 2018 - 95 of 119 -

Bonded screen where the difference in diameter is less than 2mm

31. Remove the screen to 40mm from the sheath cut. 29

Note for this type of screen no dry graphite is required

32. Cut the core to 235mm from the sheath cut. Remove insulation and chamfer

Bonded screen where the difference in diameter is more than 2mm

33. Remove the screen to 20mm from the sheath cut. 29

ST:CA3V/4 October 2018 - 96 of 119 -

34. Cut the core to 235mm from the sheath cut. Remove insulation and chamfer

35. Apply adhesive tape (sticky side out) from the beginning of the insulation.
Ensure the edge is straight and clean.

36. Wearing disposable gloves and using a new, clean workhorse wipe apply the dry
graphite (Pfisterer part number No. 003 010 011) to the roughened insulation.
Allow to dry before buffing off excess with a clean dry wipe

37. Remove protective Scotch 88 tape and proceed to 38 --

38. Park the heatshrink tube and bell flange onto the cable

39. Apply adhesive tape (sticky side out) over the conductive layer (if required). Put
adhesive tape over the ends of the strands and apply Pfisterer MV-special grease to
the insulation before removing the tape from over the conductive graphite layer.

ST:CA3V/4 October 2018 - 97 of 119 -

40. Check the insulating part is clean before greasing the inside thinly and evenly with
Pfisterer MV-special grease.

41. Slide the insulating part onto the insulation until 10mm of the insulation is exposed.
Remove excess grease.

42. Remove the tape from the conductor before sliding on the thrust piece (rounded
side towards the insulating part) and the tension cone.

Tension
cone

Thrust
piece

NOTE. The conductor must not protrude out of the tension cone

43. Slide the contact ring onto the tension cone

ST:CA3V/4 October 2018 - 98 of 119 -

44. Fix the contact ring onto the tension cone with the impact hammer. The contact ring
must no longer rotate

45. Slide the retaining ring of the compression head back and fix the half-shells behind
the thrust piece. Do not damage the insulator.
Retaining ring

46. Squeeze the half-shells together and slide the retaining ring forwards. Turn the
knurled wheel [1] of the hydraulic compression tool to the right until the insert of
the compression tool makes contact with the contact ring. Pump the hydraulic
compression tool until it reaches pressure. To release use lever 2.

47. Slide the insulating part flush against the thrust piece.

ST:CA3V/4 October 2018 - 99 of 119 -

48. Slide the bell flange onto the insulating part.

49. Clean the surface of the insulating part and the surface of the socket with De-solvit
and grease thinly and evenly with Pfisterer MV-special grease. (wear disposable
gloves).

50. Introduce the termination to the socket and tighten the screws. Note the bell flange
must be held until the screws grip. Tighten the screws all around with the SW6 T-
handled screwdriver (torque 15Nm)

51. Check that you have 207mm to your check mark tape

ST:CA3V/4 October 2018 - 100 of 119 -

52. Apply another layer of sealing tape directly over the first. Ensure that the voltage
tap wire does not cross the screen wires and runs parallel for a minimum of 10mm.

53. Slide up the heatshrink tube and fully shrink down.

NOTE. A setting time of 1 hour is needed before energising

54. Cut the screen wires to the required length and connect to the earth stud. The
voltage tap wire should be connected to the constant voltage indicator system. If
this is not required it must be connected to earth with the screen wires.

ST:CA3V/4 October 2018 - 101 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.410

630 & 800mm2 COPPER WIRE SCREEN CABLE 33kV PFISTERER SIZE 3XL INNER
CONE SEPARABLE CONNECTOR TERMINATIONS.

Note: - To complete this termination bespoke Pfisterer tooling is required.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 102 of 119 -

JOINTING PROCEDURE 7.410

MATERIALS LIST CABLE SIZE – 630mm² CWS

Item Quantity

Pfisterer inner cone size 3XL base module (set of 3) 1

Pfisterer 630mm² cable size module 1
Connector BET120-12 1
Compression gland 3
Atlas two bolt cable cleat 3

MATERIALS LIST CABLE SIZE – 800mm² CWS

Item Quantity

Pfisterer inner cone size 3XL base module (set of 3) 1

Pfisterer 800mm² cable size module 1
Connector BET120-12 1
Compression gland 3
Atlas two bolt cable cleat 3

ADDITIONAL ITEMS FOR EACH JOINT

PVC Tape
De-solvit 1000 FD
Workhorse dry wipes
Emery cloth
Cable ties
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual

Note 2: - To complete this termination bespoke Pfisterer tooling is required e.g.

mechanical hydraulic compression tool, size 3 compression head, size 3 impact head and
SW6 Torx head screwdriver.

This jointing procedure is only to be used on cables with outside diameter < 58 mm
namely:-

Cable Size - CWS Outside Diameter of cable.

630mm² 59.9mm
800mm² 64.5mm

Note 3: - The cable has to be straight; it needs to be aligned after heating using heating
tubes and straightening devices.

ST:CA3V/4 October 2018 - 103 of 119 -

 JOINTING PROCEDURE 7.410

Actions General Requirements

(ST: CA3C/3)

1. Ensure cable box dimensions are suitable for termination. --

2. Identify and mark core phasing clear of termination position. --

3. Set and align cores into their termination positions. 5/6

4. Clean each oversheath for a distance of 2m. --

5. Heat and straighten the cores. 8

6. Apply a temporary earth continuity bond clear of termination 11

position.

7. Park a mastic lined heat shrink tube next to temporary earth

continuity bond of each core. --

8. Park heatshrink tube and pre-assembled bell assembly over cable. --

9. Set and mark cores into their required positions and mark position (1).
This position will be the datum mark for the whole termination 6

* denotes the screen termination cut position L= min 210mm

10. Cut each core to allow sufficient length of copper wire screen to
terminate to its connection point to earth --

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11. From the datum mark (1) previously applied in 9, place a
further mark 290mm towards the cable --

Note: -Position 1 becomes the datum line for the procedure.

12. Remove oversheaths and bedding tapes. 17

13. From the oversheath termination mark 270mm and abrade

the oversheath 18

14. Clean the abraded oversheath. 40

15. Apply a turn of mastic tape 390mm from the datum line
around oversheath.

1
390

40
600

16. Straighten copper screen wires and bend back over oversheath
termination ensure copper screen wires are spaced evenly into
mastic tape applied. --

17. Hold copper screen wires in place on the oversheath

by applying Scotch 88 tape 40mm form the oversheath. --

18. Important - Place a mark 600mm from (1) the datum mark
and apply Scotch 88 tape. --

ST:CA3V/4 October 2018 - 105 of 119 -

19. Apply another layer of sealing tape directly onto the first one
to sandwich the earth wires. --

EASI-STRIP Semi-Con Screen Only (for bonded screens see 27)

20. Measure a length of 210 mm from the mark oversheath

termination (1) and cut excess off with a hacksaw. 27

Note: – do not use cable croppers.

21. Measure 10 mm from the datum mark and remove the easy-strip
semi-con screen. (do not use this measurement for a bonded screen) 25

22. From the datum position (1) apply a mark

to the insulation at 125mm. --

23. Remove the phase insulation to the mark applied in 22. 28

24. Apply Scotch 88 tape to protect the conductor end --

25. From the datum mark (1) measure 40mm

onto the insulation apply a mark. --

26. Using a new and clean Workhorse wipe apply the dry graphite
(Pfisterer part number No. 003 010 011) to the roughened insulation. --

ST:CA3V/4 October 2018 - 106 of 119 -

FULLY BONDED Semi-Con Screen Only

27. At about 300 mm and 400 mm in front of the oversheath

termination (1) remove the semi-conducting layer for
checking. Then measure the difference from semi-con
layer to peeled insulation using the diameter tape. 25

Measure
OD of semi-conducting layer – OD of insulation
difference < 2 mm means normal semi-con screen.
difference > 2 mm means thick semi-con screen.

28. Measure a length of 210 mm from the mark oversheath

termination (1) and cut excess off with a hacksaw. 27

29. Remove the fully bonded semi-con screen to the dimensions below 25

Screen thickness Distance From Datum

Up to 2mm 40mm
More than 2mm 20mm

30. From the datum position (1) apply a mark

to the insulation at 125mm. --

31. Remove the phase insulation to the mark. 28

32. Apply Scotch 88 tape to protect the conductor end --

ST:CA3V/4 October 2018 - 107 of 119 -

 FOR BONDED SCREENS THICKER THAN 2mm ONLY

33. From the datum mark (1) measure 40mm

onto the insulation apply a mark. --

85

34. Using a new and clean Workhorse wipe apply the dry graphite
(Pfisterer part number No. 003 010 011) to the roughened
insulation. --

Completion of the Preparation

35. Remove the Scotch tape from the insulation and apply 3mm chamfer
to the phase insulation. --

36. Degrease the phase insulation ONLY. 40

37. Apply crepe paper under slight tension and using half
lap layers from the oversheath termination (1) up to
the screen wires. --

38. Apply copper knit mesh under slight tension and using half
lap layers over the crepe paper from the oversheath termination (1)
to 20 mm over the screen wires. --

39. For EASI-STRIP screens only - Stretch a length of semi-con tape to obtain
approximately a half of its original width, apply 2 layers to the dimensions shown
below. For easy-strip semi-con screens the edge of semi-con screen must be
wrapped

ST:CA3V/4 October 2018 - 108 of 119 -

Note: - To prepare the tape take the end and pull to allow the tape to
break this will form a thin tapered end, on finishing press on the tape
and pull to allow the tape to break, press the thin tapered end down to secure.

Assembly

40. Apply Scotch 88 tape with adhesive side outward to

the dry graphite. --

41. Clean insulation 40

42. Apply thin and even Pfisterer MV special grease to insulation. --

43. Remove protective wrapping from dry graphite. --

44. Check the stress cone is clean and apply a thin and even
layer of Pfisterer MV special grease inside --

Note: - Only use the silicon grease supplied within the termination kit by
the manufacturer.

45. Push the stress cone, smoothly and without twisting, onto
the core until approximately 10mm of the insulation is
protruding beyond the end of the installed stress cone --

ST:CA3V/4 October 2018 - 109 of 119 -

46. Remove any excess silicon grease and PVC tapes applied
to conductor in 33. --

47. Slide the tension cone onto the conductor --

Note: - Ensure the round surface edge of the thrust piece and the
conductor hole recess is facing towards the cable to allow the
insulation to fit into the recess, and the rounded edge to fit into
the stress cone end recess.

48. Slide the contact ring as far as possible onto the tension
cone by hand. --

ST:CA3V/4 October 2018 - 110 of 119 -

Note: - Check the conductor does not protrude beyond the end of the
end of the tension cone.

49. Using the impact device placed over the contact ring, gently tap the
rounded end to allow a stable and secure fit of the contact ring to
the tension cone, the ring should no longer be able to turn --

Note: - The impact head is to be hit only with the palm of the hand.
DO NOT USE ANY FORM OF TOOL.

50. Without twisting, push the stress cone further down the cable in
order to allow sufficient space (l0mm approximately) to allow
fitting of the hydraulic compression tool behind the thrust
piece, complete the compression operation --

51. On completion of the compression operation, push the

stress cone, without twisting back towards the thrust
piece until the stress cone and thrust piece meet. --

ST:CA3V/4 October 2018 - 111 of 119 -

52. Push the bell flange onto the insulating part. --

53. Slide back the conical element from the end of the bell flange. --

54. Clean the surface of the stress cone and apply a thin and even
layer of PFISTER MVspecial grease . Use protective gloves 40
Note: - Only the silicon grease supplied within the termination kit by
the manufacturer is to be used.

55. Clean the bushing inside. Apply thin and even Pfisterer MV
special grease to the inside of the bushing. Use protective gloves --

56. Insert the separable connector into the bushing. Ensure the
reference line on the plastic inner sleeve of the bell assemble is
parallel with the face of the metal flange of the bushing and that
the fixing bolts align. --

ST:CA3V/4 October 2018 - 112 of 119 -

57. Tighten the fixing screws alternately in stages to complete
clamping to a torque 15Nm and refit the conical element --

58. Ensure the bell assembly is fitted and secure, position

refer to JP3D 7.410.11. --

59. Check the fit of the separable connector: The control mark
must be at 620 mm behind the bell flange – or else push
the cable to right position. --

Note: -Leave the control mark on the cable (do not remove it).

Note: -.

60. Shrink the heat shrink tube. Start shrinking at the bell and shrinking
down towards the cable --

61. Heat the shrink tubing evenly beginning at the bell flange
until it evenly encloses the former and the internal adhesive
protrudes on both sides --

62. Form copper screen wires into a bunch terminating into

an earth connector, connect to the earth stud/bar refer --

63. Connect the voltage tap earth lead from the bell assembly
to the earth stud/bar. --

ST:CA3V/4 October 2018 - 113 of 119 -

64. Apply relevant phase identification tape to the cable oversheath
refer to JP3D 7.410.12. --

65. Remove temporary earth continuity bond applied in 5

and reseal oversheaths with heatshrink tubes applied in 6. 11/45

66. Fit and secure cables into cable cleats refer to JP3D 7.410.13. --

ST:CA3V/4 October 2018 - 114 of 119 -

 Serving the Midlands, South West and Wales
Gwasanaethu Canolbarth a De Orllewin Lloegr a Chymru

ST: CA3V/4 PROCEDURES FOR MAKING 33kV CABLE TERMINATIONS

JOINTING PROCEDURE 7.411

INSTALLATION OF PFISTERER SIZE 3 INNER CONE SURGE DIVERTERS.

Note: - To complete this installation no bespoke Pfisterer tooling is required.

This procedure is to be read in conjunction with the appropriate

General Requirements ST: CA3C/3 Section 6
of the 33kV Jointing Manual

ST:CA3V/4 October 2018 - 115 of 119 -

JOINTING PROCEDURE 7.411

MATERIALS LIST SURGE DIVERTER – 827 537 360 or 450

Item Quantity

Pfisterer size 3 surge diverters (each) 3

Pfisterer Part number 827 537 360 #
Pfisterer Part number 827 537 450 – Cornwall only #

# = These two items are on a call off contract with Pfisterer see ST: CA3X for the E 5
numbers.

ADDITIONAL ITEMS FOR EACH JOINT

PVC Tape
De-solvit 1000 FD
Workhorse dry wipes
Emery cloth
Cable ties
Aluminium oxide cloth 320 grit
Aluminium oxide cloth 400 grit

Note: - Individual material item numbers (E 5) are to be found in Section 4 of the 33kV
Jointing Manual

Note 2: - Bespoke Pfisterer tools are required to carry out this installation.

ST:CA3V/4 October 2018 - 116 of 119 -

 JOINTING PROCEDURE 7.411

Actions General Requirements

(ST: CA3C/3)

Refer to Drawings JP3D 7.411.1 whilst undertaking this Jointing Procedure.

1. Clean the inner area (3) of the equipment interface bushing. --

2. Thoroughly grease the inner area with the special grease provided. --

3. Insert the male section of the surge diverter along with a --

ventilation hose to bleed the air out of the female section of
the bushing.

4. Remove the ventilation hose and tighten the fixing screws to 15Nm. --

5. Connect the surge diverter to earth via a 35mm² green/yellow --

PVC cable.

ST:CA3V/4 October 2018 - 117 of 119 -

 APPENDIX A

SUPERSEDED DOCUMENTATION

This document replaces ST:CA3V/3 dated August 2017 which should now be withdrawn.

APPENDIX B

ASSOCIATED DOCUMENTATION

ST:CA3A/2, ST:CA3C/3, ST:CA2M/4, ST:CA2N/4, ST:CA2O/3, ST:CA2S/3, ST:CA2T/3,

ST:CA2V/4.

APPENDIX C

KEY WORDS

33kV indoor and outdoor terminations, 33kV compound replacement terminations, 33kV
load break connectors, 33kV dead break separable connectors.

ST:CA3V/4 October 2018 - 119 of 119 -